Method of winding layer wound magnet coils



July 10, 1951 G. H. LELAND 2,559,824

METHOD OF' WINDING LAYER WOUND MAGNET COILS Filed Nov. l2, 1947 4 Sheets-Sheet 1 l r 1 )I BY M July 10, 1951 G. HKLELAND METHOD OF- WINDING LAYER WOUND MAGNET COILS 4 Sheets-Sheet 2 Filed NOV. l2, 1947 lil.

INVENTOR. G50/66E /74 '2 7A/0 BY @fraai/Ey- G. H. LLAND METHOD OF WINDING LAYER WOUND MAGNET COILS Filed Nov. l2, 1947 Juiy 1o, 1951 4 Sheet's-She'et 3 INVENTOR. 675066Z: l/7N@ Q INVENTOR.

4 Sheets-Sheet 4 G. H. LELAND METHOD 0F WINDING LAYER WOUND MAGNET COILS July 10, 195i Filed Nov. l2, 1947 Patented July 10, 1951 .METHOD OF WVINDING LAYER WOUN D MAGNET COILS AGeorge H. Leland, Dayton, -Ohio Application November 12, 1947, Serial No. 785,214

7 Claims.

This invention relates to precision Wound magnetic coils and the method of producing the same.

One object of the invention is to provide a coil including in a given space more copper than has been heretofore possible, thus providing increased efliciency in the coil.

A further object of the invention is to provide a coil which may be wound of much liner wire, at higher speed, and with less mechanism than is possible with conventional coils.

A further object of the invention is to provide a coil which is wound in layers of one-half turn multiples, thereby providing more flexible design limits.

.frfurtherobject of the invention is to provide a coil in which the two sides of the coil are symmetrical andthe scroll layer reversals are equal and less prominent than in the conventional coil.

A further objectof the invention. is to provide a sinipleeflicient method of winding such a coil.

A .further object of the invention is to provide method by which such coil may be wound at high speed and with extreme accuracy.

.A further object of the invention is to provide a simple and relatively inexpensive mechanism by which such a coil may be wound in accordance with said method.

Other objects of the invention may appear as it isdescribed in detail.

In the accompanying drawings Fig. 1 is ,a side elevation of a coil embodying my invention, on an enlarged scale; Fig. 2 is an edge view of such a coil; Fig. 3 is a section taken on the line 3-3 of Fig. 1; Fig. 4 is a perspective view of a coil wound and tied; Fig. 5 is an elevation of one end of a form on whichthe coil is to be wound; Fig. 6 is a longitudinal sectional view of such a form taken on the line 6-6 of Fig. 5; Fig. l is a side elevation, partly in section on line 1 7 of Fig. 5, showing the same separated to permit the removallof the wound coil; Fig. 8 is an elevation of the right hand end member of the form of Fig. 7 looking in the direction of the arrows; Fig. 9 is a section taken on the line 9-9 of Fig. 6; Fig. 10 is a layout of the four segments of the form showing the same in their relative axial positions; Fig. 1l is a longitudinal sectional view, partly broken away, through one of said segments; Fig. 12 is a longitudinal section, partly broken away, through another of said segments; Fig. 13 is a plan View showing the -feeding of the wire from a tension device to the form; Fig. 14 is a layout of a modified arrangement oi the segments; Fig. 14a is a side elevation of a coil wound on the segments arranged as in Fig. 14; Fig. 15 is a layout of mod- (Cl. L10-92.2)

2 ied segments; and Fig. 16 Vis a diametrical section, lpartly broken away, taken through the ltwo scrolls of a coil wound in accordance with the invention.

In .the construction in Figs. 1 to 13 the invention is embodied in a layer wound magnet coil 'in which leach full `turn of wire in each layer comprises two one-half turns 2Q, each succeeding halt turn being axially shifted, or offset, Ifrom the next preceding half turn, as shown at '21. Each shift in each layer is in -the same axial direction and the shifts ineach succeeding layer are in the direction opposite `the -direction of Athe shifts in the next preceding layer. Each half turn-of Wire in each layer has its major portion in a plane at right angles to the axis yof the coil and adjacent planes are spaced one vfrom the other a Adista-nce approximating, and usually slightly exceeding, one-half of the `'diameter of the wire. Each half turn also has a relatively short oblique end po`rtion, or shift, which connects the same with the next succeeding :and axially shifted half iturn, this shift preferably 'being inthe form of an vS- curve. .Each 4layer has the same numberof turns .andieach half turn of each succeeding layer iis in `a plane .between `and spaced substantially equal distances from the .pla-nes of the two adjacent half turns in the .next ,precedinglayen so thatthe half turns of each `succeeding or outer -layer lie in the grooves formed between the outer surfaces .of the 'half turns of the next preceding or'inner layer. Thus the axial.spacing of the half turns in one layer with relation to the half turns i-n an adjacent layer` is Aapproximately .one-.half the `diameter of the Wire, Vwhich results in .relatively smooth and symmetric side surfaces for the coil. The half turn .shifts of the wire .produce two scrolls, or overlaps, 22 in each side of 'the coil and due to the spacing of the layers these scrolls are relatively smooth and inconspicuous.

The coil is wound by connecting the end por-.tion 423 of a .length of wire with a suitable form `and rotating the form Vto -Wind Ithe -wire thereon, Fig. 13. The form preferably has within-itself means for `Vguiding the wire in closely placed turns .and for reversing the direction of the movement of the lwire at the end of each layer, so that no YeX- ternal Alead guiding means is required, it .being only .necessary to provide frictional resistance to Athe .longitudinal movement of the wire suiilcient to cause it to .wind tightly on the form. As the wire is wound `onto .the form and the first half turn approaches completion the .wire is shifted ,axially of the form to locate the succeeding half Iturn in a plane spaced from the plane of the first half .turn a distance approximating one-half the diameter of the wire, as shown at 2id, and as the second half turn approaches completion the wire engages the rst half turn, at a point adjacent the point at which the wire is connected with the form, and is moved axially thereby to provide the second half turn with an axial shift, at 2 lb, and to locate the third half turn in a plane spaced axially from the plane of the second half turn the same distance as the second half turn is spaced from the first half turn. Each succeeding turn of the wire causes the same to engage the next preceding full turn and the shifts in each preceding full turn impart corresponding shifts in each succeeding full turn until the layer is completed. Upon the completion of each layer the wire is superimposed on the preceding layer and the direction of movement of the wire lengthwise of the coil is reversed and the succeeding layer is wound in half turn increments as determined by the half turn shifts in the next preceding layer.

While I have shown and described the coil as comprising a single length of wire wound in half turn increments it is obvious that the coil may be wound in other fractional parts of a full turn and that it may be wound from a plurality of lengths or strands of wire.

The form on which the coil is wound may be of any suitable character but I prefer the form shown in the drawings, which has been highly satisfactory in operation. As shown in Figs. 5 to l2 the form comprises a grooved and collapsible cylindrical structure having side walls at the respective ends thereof. The side walls being separable to permit the removal of the wound' coil when the grooved structure is collapsed. The side walls and 26 are spaced axially one from the other a distance equal to the axial length of the coil to be wound thereon. The side wall 25 has a hub portion 21 which is mounted on and rigidly secured to a driving shaft 28. The side wall 26 is rigidly secured to a shaft 29 in axial alinement with the shaft 23, the side wall 26 and the shaft 29 being axially movable with relation to the side wall 25. When the side walls are in coil winding positions they are rigidly connected one with the other for rotation in unison. The cylindrical structure arranged between the side walls comprises a plurality of segments which are normally supported in positions in which their outer surfaces are concentric with the axis of the form but which are movable radially to collapse the same and release the wound coil therefrom. Inithe present arrangement there are four segments arranged in pairs, the segments 30 constituting one pair and the segments 3l constituting a second pair. Each segment is provided with Ya longitudinal series of transverse grooves, the corresponding grooves of the segments of each pair constituting in eiect a single groove of a circumferential length slightly less than one-half of the over-all circumference of the cylindrical structure. The segments are connected with the side wall 25 but are movable with relation thereto for a purpose which will hereinafter appear. As shown the wall 25 is provided with an axial cavity 32 and the adjacent ends of the segments, as shown at 33, are of reduced thickness and extend into said recess. The wall 25 is provided, in radial alinement with the end portion of each segment,

with a bore 35 in which is slidably mounted a plunger 36 having at its inner end a head 3T which enters a cavity in the end portion in the corresponding segment. The plunger is urged into contact with the corresponding segment by a spring 38 coiled about the plunger between the head 31 thereof and a hollow plug 39 threaded into the outer end of the bore 35 and in which the plunger is slidably supported, The inner surfaces of the several segments converge toward the hub 21 of the side wall 25 so as to provide a tapered opening to receive an expanding and supporting element. As here shown the supporting element is in the nature of a conical element 40 projecting from the side wall 26 and so arranged that when the side walls are in coil winding relation one to the other the conical element 4D extends into the space between the segments and expands the latter to coil winding positions, in which positions each individual segment is spaced circumferentially a slight distance from the adjacent segments, as best shown in Fig. 9. In the arrangement shown, the inner end of the conical element 46 is provided with recesses 40a adapted to receive studs 46D rigidly mounted in the hub portion of the side wall 25 and thus rigidly connect the two side Walls for rotation in unison.

The grooves in the two pairs of segments are arranged in planes perpendicular to the axis of the form and so spaced axially of the form that the planes of the grooves in one pair of segments lie between the planes of the grooves in the other pair of segments, each plane being spaced from the two adjacent planes a distance approximating, and usually slightly exceeding, one-half of the diameter of the wire to be wound. In the particular arrangement illustrated the side wall 26 is provided with an oblique slot 4I to receive the end portion 23 of the wire which is to be wound and to connect the same with the form for rotation therewith. The groove 42 at that end of the segments 30 adjacent the side wall 26 is in a plane spaced from the side wall 26 a distance approximating one-half of the diameter of the wire and the receiving end of that groove is s0 located with relation to the slot 4l that the wire will be wound into that groove. The groove 43 at that end of the segments 3i adjacent the side wall 26 is in a plane spaced from the side wall 26 a distance approximating the full diameter of the wire to be wound and the outer inclined wall of said groove extends to the inner surface of the side wall 26. Thus as the form is rotated and the rst half turn of the wire approaches completion, the wire engages the extended outer inclined surface of the groove 43 and is guided into that groove so that the second half turn is located in a plane spaced axially from the plane of the first half turn a distance approximating one-half the diameter of the wire. As the second half turn approaches completion the wire engages the first half turn at a point adjacent the connection of the latter with the side wall M and is thus deflected axially into the succeeding groove in the adjacent segments 36, and as the rotation of the form continues the wire is wound in Contact with the preceding half turns and the shifts of those half turns impart corresponding half turn shifts to the wire until the layer has been completed.

\ The grooves are here shown as V-shaped in cross section and the plane of each groove extends through the apex of the groove but it is to be understood that the grooves may be of any suitable cross sectional shape. The plane of the groove 44 at that end of segments 3i!y which is adjacent hte side wall 25 is spaced from that side wall a distance equal to the full diameter of the wire and the plane of the corresponding groove 45 in segments 3! is spaced from the side wall 25 a distance approximating one-half the diameter Aof the wire. Thus the first half turn Iof the last fullturn ofthe rst layer will be spaced from rthe lside lwall `25 andthe second half turn of the last full turn will .be in contact with that side wall andas said .second half turn is completed the wire will ride over the first half turn ofthe last .full vturn Vand will be supported'between that half turn and the side wall. As the rst half turn of the succeeding winding approaches completion ,the wire engages the shift in the last full turn and .is moved axially of the form to impart an axial shift to the first half urn of said succeeding winding. Thereafter the wire falls in the .groove between adjacent turns of the preceding layer and each shift in the precedinglayer imparts a corresponding shift to the turns in the succeeding layer in a direction opposite the direction of the shifts in said preceding layer.

The fully wound coil is tied, as shown in Fig. 4, toprevent the relative diplacement of the .windings when the coil is removed from theform. For this purpose both side walls of the form are provided respectively with radial slots 41 and 48 .through which a cord Amay be inserted prior to the winding operation and then tied about the coil after the latter has been completely wound. When the coil has been completely wound and tied the side wall 25 and conical element 4.53 are retracted, thereby releasing the segments and permitting the same to be moved inwardly by the spring pressed plungers to contract the cylindrical structure and thus release the wound coil. As .has been explained the segments are spaced one from the other when in winding positions and as the conical element is withdrawn the segments are pressed inwardly by the plunger and as they move inwardly are maintained in annular rela- .tion ,by the conical element until the edges of adjacent segments have contacted one with the other and are thus self supporting and in a position to permit the conical element to be again inserted therein. When'the side walls have been thus separated the coil is removed from the segments, the conical element reinserted in the segments and the Iform is ready for winding another coil. As has been stated the construction of the form .is such that no outside .lead guidance is required and the wire to be wound is carried from the supply coil, given two or three turns about a friction element l, spaced a short distancefrom the form, and the end of the wire is then connected with the form for rotation therewith, the resistance oered by the friction element being such as to maintain the wire taut and to wind the same tightly on the form.

It is sometimes desirable that leach layer `ofa coil shall comprise a given number of full turns and an additional half turn. For this purpose the'direction of movement of the wire lengthwise of the coil is reversed at the end of the half turn following the Ylast full turn in each layer and in Fig. there is shown an arrangement of grooved segments whereby this maybe accomplished. As there shown the two segments C which are rst engaged by the wire are identical, all of the grooves in each segment being of the same width and the corresponding grooves in the two segments being in the same plane. The other two segments, D, are also identical and the corresponding grooves therein are in the same plane, but each segment D has at each end thereof a wide groove 49, similar to groove 43 of Fig. 10. The grooves in segment D are in planes between the planes of the adjacent grooves in segments C. The outer inclined surfaces of the wide grooves 49, adjacent the side wall 26, shift the second half of the first turn of the rst layer in the manner above described. The wire completes its last half turn as it leaves the last groove in segments C, adjacent side wall 25, -as shown at la, .and passes to and is wound on the last preceding full turn, thus terminating the layer in a .half turn. Thereafter the wire is shifted inwardly at the end of a half turn at each 'end of each layer, so that each layer terminates in a .half turn, the half turn of each succeeding layer being at that end of the coil opposite thc half turn of the next preceding layer.

The coil may be formed from two or more separate lengths of wire wound simultaneously in part turn increments and simultaneously shifted at the end-of each succeeding part turn. In Fig. 14 there is shown an arrangement of segments for winding two lengths of wire simultaneously in quarter turn increments. Each of the four segments, E, F, G and H, is provided at one end with a wide groove 50, the wide grooves of segments E and G being at those ends of the segments which are adjacent the sidewall .25,

and the widegrooves oi segments F and H being at those ends of the segments adjacent the opposite side wall 25. Each groove of segment F is spaced from the corresponding groove in 'segment E a distance approximating onehalf the diameter of the wire being wound, each groove in segment G is spaced from the corresponding groove in segment F' the same distance, and each groove in segment H is spaced from the corresponding groove in segment G a like distance. The form rotates in the direction from segment H to segment E. A wire l enters the form at the leading edge of segment E and a second wire 2 enters the form at the leading edge of seg-- ment G. As the form rotates the rst quarter turns of the two wires are wound, respectively, in the adjacent end grooves of segments E and G and the second quarter turns thereof enter, respectively, the wide grooves of segments F and H, and are shifted inwardly thereby. Upon the third quarter turn of the form the wire l contacts wire 2 adjacent its point of entrance and is deected thereby into the second groove of segment G, and the wire l then engages the deflected portion of wire 2 and the fourth quarter turn of Wre I is deected into the second groove of segment H. The continued rotation of the form causes the wire 2 to engage and to be shifted by the successive shifts in the preceding turns of wire I and wire l likewise engages and is shifted by the shifts of wire 2. The wire i completes the last full turn of the first layer as it passes from the segment H, as shown at la, and passes vto the second layer where it is wound on the preceding turns of the first layer. The wire 2 completes its last full turn of the first layer as -it passes from the segment F, as shown at .2a. and passes to the next layer and is Wound onto the preceding turns. Thus each layer is formed of multiples of quarter turns and is provided at each side thereof with four scrolls as shown in Fig. 14a.

While I have shown and described one embodiment of my invention with minor modican tions thereof, l wish it to be understood that I do not desire to be limited to the details thereof as various. modifications may occur to a person skilled in the art.

Having now fully described my invention what I claim as new and desire to secure by Letters Patent is:

1. A method of winding a layer wound magnetic coil which comprises winding in each layer multiple wires in part turn increments, each increment being in a plane perpendicular to the axis of the coil, and shifting each succeeding part turn in each wire in each layer in the same direction lengthwise of the axis of the coil with relation to the next preceding part turn in said layer, the several shifts in each wire in each layer being of a combined axial length slightly greater than the combined diameters f said multiple wires.

2. A method of winding a layer wound magnetic coil which comprises winding a length of wire` about a xed axis in half turn increments to form a layer of turns of uniform diameter, each half turn being in a plane perpendicular to said axis, and shifting each succeeding half turn lengthwise of said axis with relation to the next preceding half turn in said layer a distance slightly greater than one-half the diameter of the wire.

3. A method of forming a magnet coil which comprises winding a length of wire about a ixed axis in half turn increments to form a layer of 'turns of uniform diameter, each half turn being in a plane perpendicular to said axis, shifting each succeeding half turn in said layer lengthwise of said axis with relation to the next preceding half turn a distance slightly greater than one-half of the diameter of the wire, reversing the direction of movement of said wire lengthwise of said axis to superpose a second layer of turns on the previously formed layer of turns and shifting each succeeding half turn of said second layer with relation to the next preceding half turn therein a distance slightly greater than onehalf the diameter of the wire in a direction opposite the direction in which the succeeding half turns of the rst layer of turns were shifted.

4. A method of forming a magnet coil which comprises winding a length of wire about a xed axis in increments of one-half turn, with each increment in a plane perpendicular to said axis, shifting the second half turn in each layer lengthwise of said axis with relation to the first half turn in that layer a distance slightly greater than one-half the diameter of the Wire, thus forming an oblique section of wire between said half turns, winding the third half turn in narrowly spaced relation to the rst half turn and against the leading end of said iirst turn to shift said third half' turn axially if said coil with relation to the rst half turn a distance slightly greater than one-half the diameter of said wire, and winding the fourth half turn in narrowly spaced relation to the second half turn and against the oblique section between the rst and second half turns to shift said fourth half turn alilie distance with relation to the second half turn, and then winding each succeeding half turn in said layer against only the oblique section between the two next preceding half turns,

whereby each half turn in said layer is shifted axially of said coil with relation to the next preceding half turn a distance slightly greater than one-half the diameter of the wire.

5. A method of winding a magnet coil to automatically lead the wire into succeeding turns in succeeding layers, which comprises rotating a winding form to wind a length of wire thereon. guiding said wire by contact with said form into succeeding turns through each layer in half turn increments, each in a plane perpendicular to the axis of the oil, and shifting each half turn in each layer lengthwise of the axis of said coil with relation to the next preceding half turn therein a distance slightly greater than one-half the diameter of the wire being wound.

6. The method of winding a layer would magnet coil which comprises winding two parallel lengths of wire simultaneously in quarter turn increments and shifting succeeding quarter turns of both wires axially of the coil with relation to the next preceding quarter turns of the respective wires.

7. The method of winding a layer wound magnet coil which comprises connecting two separate lengths of wire with a winding form at points in a plane perpendicular to the axis of the form and spaced circumferentially one from the other, rotating said form to wind said wires thereon in quarter turn increments, shifting each quarter turn of each wire in each layer axially of the coil at the end of the rst quarter turn thereof a distance slightly greater than one-half the diameter of the wire, shifting the third quarter turn of the leading wire axially of the coil a like distance as it engages the first quarter turn of the second wire and thereafter simultaneously shifting adjacent quarter turns of the two wires at the end of each preceding quarter turn thereof.

GEORGE H. LELAND.

REFERENCES CITED The following references are of record in the le of this patent:

UNITED STATES PATENTS Number Name Date 180,169 Tasker July 25, 1876 535,105 Heath Mar. 5, 1895 1,167,720 Scott Jan. 11, 1916 1,167,721 Scott Jan. 11, 1916 1,167,722 Scott Jan. 1l, 1916 1,167,723 Scott Jan. 11, 1916 1,172,910 Scott Jan. l1, 1916 1,253,166 Frank et al Jan. 8, 1918 1,501,787 Lacy July 15, 1924 2,140,137 Merkle Dec. 13, 1938 2,420,050 Mande May 6, 1947 2,441,564 Combs May 18, 1948 FOREIGN PATENTS Number Country Date Germany Nov. 4, 1922 

